Form No. 3420-710 Rev B Z Master® Professional 6000 Series Riding Mower with 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74946—Serial No. 402000000 and Up Model No. 74947—Serial No. 402000000 and Up Model No. 74969—Serial No. 400000000 and Up Register at www.Toro.com.
Introduction It is a violation of California Public Resource Code Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire. This rotary-blade, riding lawn mower is intended to be used by professional, hired operators.
Contents Model No. Safety ....................................................................... 4 General Safety ................................................... 4 Slope Indicator ................................................... 5 Safety and Instructional Decals .......................... 6 Product Overview ................................................... 12 Controls ........................................................... 12 Specifications ..................................................
Safety Replacing the Low-Pressure Fuel Filter.............................................................. 47 Servicing the High-Pressure Fuel Filter............. 47 Servicing the Fuel Tank..................................... 47 Electrical System Maintenance ........................... 48 Electrical System Safety ................................... 48 Servicing the Battery......................................... 48 Servicing the Fuses ..........................................
Slope Indicator g011841 Figure 3 You may copy this page for personal use. 1. The maximum slope you can operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decal93-7818 93-7818 decalbatterysymbols 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 115 to 149 N∙m (85 to 110 ft-lb). Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance away from the battery. 2.
decal106-5517 106-5517 1. Warning—do not touch the hot surface. decal110-2068 110-2068 1. Read the Operator's Manual. decal112-9028 112-9028 1. Warning—stay away from moving parts; keep all guards in place. decal107-3069 107-3069 1. Warning–there is no rollover protection when the roll bar is down. 2. To avoid injury or death from a rollover accident, keep the roll bar in the raised and locked position and wear the seat belt.
decal116-4858 116-4858 decal116-5988 116-5988 decal117-0346 1. Parking brake—engaged 117-0346 2. Parking brake—disengaged 1. Fuel leak hazard—read the Operator's Manual; do not attempt to remove the roll bar; do not weld, drill, or modify the roll bar in any way. decal116-8726 116-8726 1. Read the Operator’s Manual for the recommended hydraulic fluid. decal117-3848 117-3848 1. Thrown object hazard—keep bystanders a safe distance away from the machine. 2.
decal119-6807 decal126-7875 119-6807 126-7875 1. Warning—no step 1. Fuse location 4. Auxiliary, 15A 2. Relay location 5. Start relay 3. Main, 20A 6. Not used decal126-2055 126-2055 1. Wheel lug nut torque 95 ft-lb (129 N∙m) (4x) 2. Wheel hub nut torque 235 ft-lb (319 N∙m) 3. Read and understand the Operator’s Manual before performing any maintenance, check torque after first 100 hours then every 500 hours thereafter. decal127-0326 127-0326 1. Read the Operator's Manual. 3.
decal125-9383 125-9383 1. Check the hydraulic fluid every 50 operating hours. 3. Check the tire pressure every 50 operating hours. 2. Read the Operator’s Manual for information on lubricating the machine. 4. Read the Operator’s Manual before servicing or performing maintenance.
decal132-0871 132-0871 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in those conditions on that day and at that site.
Product Overview g027333 g228164 Figure 4 1. Height-of-cut deck-lift pedal 6. Roll bar 2. Transport lock 7. Seat belt 3. Parking-brake lever 8. Fuel cap Figure 6 1. Information screen 2. LED status light 9. Mower deck 10. Caster wheel 4. Controls 5. Motion-control levers 3.
Audible Alarm Neutral-Lock Position The audible alarm (Figure 5) sounds if an error occurs, indicating an issue to the operator. During start-up, the alarm sounds briefly to verify functionality. Use the NEUTRAL-LOCK position with the safety-interlock system to engage and to determine the NEUTRAL position. When the alarm sounds, an error message displays on the monitor, and the LED turns red.
Operation • Note: Determine the left and right sides of the machine from the normal operating position. Before Operation • Before Operation Safety • General Safety • Never allow children or untrained people to • • • • • • • operate or service the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics. Become familiar with the safe operation of the equipment, operator controls, and safety signs.
Using Stabilizer/Conditioner Use a fuel stabilizer/conditioner in the machine to provide the following benefits: • Keeps fuel fresh longer when used as directed by the fuel-stabilizer manufacturer • Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting Important: Do not use fuel additives containing methanol or ethanol. Add the correct amount of fuel stabilizer/conditioner to the fuel.
Using the Rollover-Protection System (ROPS) WARNING To avoid injury or death from rollover, keep the roll bar in the fully raised, locked position and use the seat belt. Ensure that the seat is secured to the machine. WARNING There is no rollover protection when the roll bar is in the down position. • Lower the roll bar only when absolutely necessary. • Do not wear the seat belt when the roll bar is in the down position. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits.
Testing the Safety-Interlock System Using the Safety-Interlock System Service Interval: Before each use or daily WARNING Test the safety-interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. 1.
Positioning the Seat Changing the Seat Suspension The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable (Figure 10). The seat adjusts to provide a smooth and comfortable ride. Position the seat where you are most comfortable. To adjust, turn the knob in front either direction to provide the best comfort (Figure 12). g019754 Figure 10 Unlatching the Seat g019768 Figure 12 1. Seat-suspension knob g019755 Figure 11 1.
During Operation • Never run an engine in an area where exhaust During Operation Safety • • General Safety • The owner/operator can prevent and is responsible • • • • • • • • • • • • • • • for accidents that may cause personal injury or property damage. Wear appropriate clothing, including eye protection; long pants; slip-resistant, substantial footwear; and hearing protection. Tie back long hair and do not wear loose jewelry. Use your full attention while operating the machine.
injury or death. The operator is responsible for safe slope operation. Operating the machine on any slope requires extra caution. Before using the machine on a slope, do the following: – Review and understand the slope instructions in the manual and on the machine. – Use an angle indicator to determine the approximate slope angle of the area. – Never operate on slopes greater than 15 degrees. – Evaluate the site conditions of the day to determine if the slope is safe for machine operation.
Disengaging the Parking Brake Starting the Engine Important: Do not engage starter for more than 5 seconds at a time. If the engine fails to start, wait 15 seconds between attempts. Failure to follow these instructions can burn out the starter motor. Note: You may need multiple attempts to start the engine the first time after adding fuel to an empty fuel system.
Using the Motion-Control Levers Shutting Off the Engine CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the key and engage the parking brake when leaving the machine unattended. g004532 Figure 21 1. Motion-control lever—NEUTRAL-LOCK position 4. Backward 2. Center, unlocked position 5. Front of machine 3. Forward Driving the Machine The drive wheels turn independently, powered by hydraulic motors on each axle.
Driving Backward WARNING The machine can spin very rapidly. You may lose control of the machine and cause personal injury or damage to the machine. 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 23). • Use caution when making turns. • Slow the machine down before making sharp turns. Driving Forward Note: The engine shuts off when you move the traction-control with the parking brake engaged.
Using the Side Discharge Adjusting the Height of Cut The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Using the Transport Lock The transport lock has 2 positions, and is used with the deck-lift pedal. There is a LOCK position and an UNLOCK position for the transport position of the mower deck (Figure 24).
Adjusting the Height-of-Cut Pin Adjusting the Anti-Scalp Rollers The height-of-cut is adjusted from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by relocating the clevis pin into different hole locations. 1. Move the transport lock to the lock position. 2. Push on the deck-lift pedal with your foot, and raise the mower deck to the transport position (also the 140 mm (5-1/2 inches) cutting height position) as shown in Figure 25. 3.
Adjusting the Flow Baffle Cam Locks Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments vary by grass type, moisture content, and the height of the grass. This procedure is applicable only to machines with the flow-baffle locks. Certain models have nuts and bolts in place of the flow-baffle locks and can be adjusted the same. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle.
Position C Alternating the Mowing Direction This is the full open position. The suggested use for this position is as follows: • Tall, dense grass mowing conditions • Wet conditions • Lowers the engine-power consumption • Allows increased ground speed in heavy conditions Alternate the mowing direction to keep the grass standing straight. This also helps disperse clippings, which enhances decomposition and fertilization.
Using the Drive-Wheel-Release Valves After Operation After Operation Safety General Safety WARNING Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. • Clean grass and debris from the cutting units, mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills.
Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.
1. If using a trailer, connect it to the towing vehicle and connect the safety chains. 2. If applicable, connect the trailer brakes and lights. 3. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 34). 4. Back the machine up the ramp (Figure 35). g028043 Figure 35 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. 5. Shut off the engine, remove the key, and engage the parking brake. 6.
Maintenance Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 100 hours • Check the wheel lug-nut torque. • Check the wheel-hub slotted-nut torque. • Check the parking brake adjustment. After the first 250 hours • Change the hydraulic filters and hydraulic fluid when using any type of fluid. Before each use or daily • • • • • • • • • Check the safety system.
Maintenance Service Interval Maintenance Procedure Every 500 hours • For Kawasaki engines—replace the safety air filter. (more often in dusty or sandy conditions). • For Kohler engines—replace the spark plug(s). • Check the wheel lug-nut torque. • Check the wheel-hub slotted-nut torque. • Adjust the caster-pivot bearing. • Check the parking brake adjustment. • Change the hydraulic filters and hydraulic fluid when using Toro® HYPR-OIL™ 500 hydraulic fluid (more often in dirty or dusty conditions).
Lubrication Adding Light Oil or Spray Lubrication Greasing the Machine Service Interval: Every 100 hours Grease more frequently when operating conditions are extremely dusty or sandy. Lubricate the deck-lift pivots. Grease Type: No. 2 lithium or molybdenum grease 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
Greasing the Mower Deck 5. Service Interval: Yearly—Grease the pump-belt-idler arm. Yearly—Grease the front caster pivots (more often in dirty or dusty conditions). Yearly—Repack the front caster-wheel bearings (more often in dirty or dusty conditions). 1. Note: Keep the dust cap off until greasing is done. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2.
Lubricating the Caster-Wheel Hubs 12. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing. Service Interval: Yearly 13. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general-purpose grease. 14. Insert the second bearing and new seal into the wheel. 15. Apply a thread-locking adhesive to the second spacer nut, and thread it onto the axle with the wrench flats facing outward. 16.
Engine Maintenance Identifying the Engine Use the following graphic to identify the engine you have and proceed to the section listed below for service (Figure 43). g230521 Figure 43 1. Kawasaki engine 2. Kohler engine • For Kawasaki engine maintenance, refer to Servicing a Kawasaki® Engine (page 36). • For Kohler engine maintenance, refer to Replacing the Mower Belt (page 57). Engine Safety • Shut off the engine before checking the oil or adding oil to the crankcase.
Servicing the Air Cleaner Important: Do not attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters. Service Interval: Every 250 hours—For Kawasaki engines—replace the primary air filter (more often in dusty or sandy conditions). 7. Every 250 hours—For Kawasaki engines—check the safety air filter. (more often in dusty or sandy conditions).
Servicing the Engine Oil Engine-Oil Specifications Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: 1.8 L (61 oz) without oil filter; 2.1 L (71 oz) with oil filter g008804 Viscosity: See the table below. g037096 Figure 46 Note: Although 10W-40 engine oil is recommended for most conditions, you may need to change oil viscosity to accommodate atmospheric conditions. Using 20W-50 engine oil in higher ambient temperatures can reduce oil consumption.
4. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 5. Drain the oil from the engine (Figure 48). 6. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 49). g008804 g194610 Figure 49 g027734 Figure 48 39 7. Start the engine and drive to a flat area. 8. Check the oil level again.
Changing the Engine-Oil Filter Servicing the Spark Plug Service Interval: Every 200 hours—For Kawasaki engines—change the engine-oil filter (more often in dirty or dusty conditions). Service Interval: Every 100 hours 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 38). 2. Change the engine-oil filter (Figure 50). Ensure that the air gap between the center and side electrodes is correct before installing the spark plug.
5. Install the left hydraulic-unit shroud (Figure 51). Checking the Spark Plug Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. g009922 If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. Set the gap to 0.75 mm (0.03 inch). g206628 Figure 53 Installing the Spark Plug g009919 Figure 51 1.
Servicing a Kohler® Engine This section is only for machines with Kohler engines. If your engine looks like the one shown in Figure 55, you have a Kohler engine. Important: Refer to your engine owner’s manual for additional maintenance procedures. g001883 Figure 56 1. Air-cleaner body 4. Air-cleaner cover 2. Primary filter 5. Safety filter 3. Latch 4. Clean the inside of the air-cleaner cover with compressed air. 5. Gently slide the primary filter out of the air-cleaner body (Figure 56).
Note: Ensure that the engine is cool so that the oil has had time to drain into the sump. Installing the Filters Important: To prevent engine damage, always 3. operate the engine with both air filters and the cover installed. 1. If you are installing new filters, check each filter for shipping damage. To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it (Figure 47). Note: Do not use a damaged filter. 2.
3. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Drain the oil from the engine. g038074 Figure 60 g027934 Figure 59 5. 6. Torque the plug to 14 N·m (125 in-lb). 44 Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 61).
g009922 g027517 Figure 61 7. Dispose the used oil at a recycling center. g009919 Figure 62 1. Pull this tab out to the side in the direction of the arrow 2. Pull the shroud off this frame tab in the direction of the arrow Servicing the Spark Plug Service Interval: Every 200 hours—For Kohler engines—check the spark plug(s). Every 500 hours—For Kohler engines—replace the spark plug(s). 4. Type: Champion XC12YC 3. Pull the shroud off this frame tab in the direction of the arrow 4.
5. Checking the Spark Arrester Install the left hydraulic-unit shroud (Figure 62). Checking the Spark Plug For Machines with a Spark Arrester Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. Service Interval: Every 50 hours If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.
Fuel System Maintenance WARNING Fuel-system components are under high pressure. The use of improper components can result in system failure, fuel leakage, and possible explosion. Use only approved fuel lines and fuel filters. Servicing the Electronic Fuel-Injection System g008963 Figure 66 This machine contains an electronic fuel-injection system. It controls the fuel flow under different operating conditions. 1. Fuel filter 2.
Electrical System Maintenance 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the battery as shown in Figure 67. Electrical System Safety • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames.
Installing the Battery Charging the Battery Note: Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 67). WARNING Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from the battery. Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 0°C (32°F). 1.
Servicing the Fuses Drive System Maintenance The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component/circuit for a malfunction or short. The fuses are located on the console to the right of the seat (Figure 70). Checking the Seat Belt Service Interval: Before each use or daily To replace the fuses, remove the cover, pull out on the fuse to remove it, and install a new fuse.
Adjusting the Tracking 1. Disengage the blade-control switch (PTO). 2. Drive to an open flat area, move the motion-control levers to the NEUTRAL-LOCK position. 3. Move the throttle midway between fast and slow. 4. Move both motion-control levers all the way forward until they both hit the stops in the T-slot. 5. Check which way the machine tracks. • If it tracks to the right, loosen the bolts and adjust the left stop plate rearward on the left T-slot until the machine tracks straight (Figure 73).
Checking the Wheel-Hub Slotted Nut Checking the Tire Pressure Service Interval: Every 40 hours Service Interval: After the first 100 hours Every 500 hours Maintain the air pressure in the rear tires at 103 kPa (15 psi). Uneven tire pressure can cause uneven cut. Check the tires when they are cold, to get the most accurate pressure reading. Check and ensure that the torque of the slotted nut is 286 to 352 N∙m (211 to 260 ft-lb).
5. Removing the Clutch Shim Install the dust cap (Figure 76). 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Using an air compressor, blow out any debris from under the brake pole and around the brake spacers (Figure 78). g001297 Figure 76 1. Spring washers 3. Dust cap 2.
g010872 Figure 81 1. Feeler gauge g010870 Figure 79 1. Brake-mounting bolt B. Using needle-nose pliers, or by hand, hold the tab and remove the shim (Figure 80). Note: Do not discard the shim until the clutch is functioning properly. g010873 Figure 82 1. Feeler gauge • If the gap is less than 0.25 mm (0.01 inch), then install the shim; refer to Using the Clutch Shim (page 53). g010871 • If the gap is sufficient, proceed to the Figure 80 safety check in step F. 1. Shim C. F.
Cleaning the Engine-Cooling Fins and Shrouds Cooling System Maintenance Cleaning the Engine Screen and Engine-Oil Cooler Service Interval: Every 100 hours/Yearly (whichever comes first) 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the air-intake screen, the recoil starter, and the fan housing (Figure 84). 4.
Brake Maintenance Checking and Cleaning the Hydraulic-Unit Shrouds Adjusting the Parking Brake Service Interval: Before each use or daily 1. Disengage the blade-control switch (PTO) and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Move the seat forward. 4. Clean the debris and grass from the hydraulic-unit shrouds (Figure 85). 5.
Belt Maintenance Inspecting the Belts Service Interval: Every 50 hours Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt. Replacing the Mower Belt g026961 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
g027730 Figure 89 1. Position the belt cover 3. Ensure that the tab is under the metal catch 2. Slide the belt cover under the side catches g009038 Replacing the Hydraulic Pump-Drive Belt Figure 88 1. Clutch pulley 2. Mower belt 5. Square hole in the idler arm for the ratchet 6. Idler-grease fitting 3. Spring-loaded idler pulley 7. Belt guide 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
Controls System Maintenance Adjusting the Control-Handle Position There are 2 height positions for the control levers—high and low. Remove the bolts to adjust the height for the operator. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Loosen the bolts and flange nuts installed in the levers (Figure 91). 4.
4. Lower deck to the ground. 5. Raise the rear of machine up and support it with jack stands (or equivalent support). Note: Raise the machine just high enough to allow the drive wheels to turn freely. 6. Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat. Note: The switch is a part of the seat assembly. 7. Temporarily install a jumper wire across the terminals in the connector of the main wire harness. 8.
g008620 Figure 94 Right Motion Control Shown 1. Torque the locknut to 23 N∙m (17 ft-lb). The bolt must protrude past the end of the locknut after torquing. 2. Most resistance (firmest feel) 3. Damper 4. Medium resistance (medium feel) g009033 Figure 93 5. Least resistance (softest feel) 1. Double nuts 12.
Hydraulic System Maintenance 6. Remove 1 dipstick from the hydraulic reservoir (Figure 96). 7. Wipe the dipstick off and thread the dipstick into the reservoir. Hydraulic System Safety 8. Remove the dipstick and look at the end (Figure 96). • Seek immediate medical attention if fluid is injected Important: Do not overfill the hydraulic into skin. Injected fluid must be surgically removed within a few hours by a doctor. units with fluid, as damage may occur.
Replacing the Hydraulic Fluid and Filters Service Interval: After the first 250 hours—Change the hydraulic filters and hydraulic fluid when using any type of fluid. Every 250 hours—Change the hydraulic filters and hydraulic fluid when using Mobil® 1 fluid (more often in dirty or dusty conditions). Every 500 hours—Change the hydraulic filters and hydraulic fluid when using Toro® HYPR-OIL™ 500 hydraulic fluid (more often in dirty or dusty conditions).
Mower Deck Maintenance 9. On both sides of the deck, measure from the level surface to the front tip of the blade (Postion A) as shown in Figure 100. Note: The measurement should read 7.6 mm (3 inches) Leveling the Mower Deck Leveling the Deck 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
Note: Loosen or tighten the single-point adjustment bolt enough to move the height-of-cut plate mounting bolts at least 1/3 the length of the available travel in their slots. This regains some up and down adjustment on each of the 4 deck links. g009042 Figure 103 g027344 Figure 101 1. Adjustment nut 3. Rear deck adjustment 2. Jam nut 4. Front deck adjustment 11. 1. Single-point adjustment bolt 13.
Servicing the Cutting Blades To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand. Blade Safety g006530 Figure 104 A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product. • Inspect the blades periodically for wear or damage.
Removing the Blades Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 107). Replace the blades if they hit a solid object, or if the blade is out of balance or bent. 1. Hold the blade end using a rag or thickly padded glove. 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 106). g000553 Figure 108 1. Blade 3. 2. Balancer Repeat this procedure until the blade is balanced. Installing the Blades 1.
Removing the Mower Deck Lock out the spring-loaded deck arms before servicing or removing the mower deck. WARNING Deck-lift arm assemblies have stored energy. Removing the deck with out releasing the stored energy can cause serious injury or death. Do not attempt to disassemble the deck from the front frame without locking out the stored energy. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
8. Raise the deck struts and secure them in the raised position. 9. Slide the deck out to the right side of the machine. Replacing the Grass Deflector WARNING An uncovered discharge opening could allow the machine to throw objects toward you or bystanders, resulting in serious injury. Also, contact with the blade could occur. Never operate the machine unless you install a mulch plate, discharge deflector, or grass collection system. 1.
Cleaning Storage Cleaning under the Mower Deck Storage Safety • Shut off the engine, remove the key, wait for all moving parts to stop, and allow the machine to cool before storing it. Service Interval: Before each use or daily 1. • Do not store the machine or fuel near flames or Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
13. Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows: A. Add a petroleum-based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from the stabilizer manufacturer. Do not use an alcohol-based stabilizer (ethanol or methanol). Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. B. Run the engine to distribute conditioned fuel through the fuel system for 5 minutes. C.
Troubleshooting Problem Possible Cause Corrective Action The oil-temperature light is on and the engine rpm is low. 1. The engine-control unit has limited engine rpm, known as “limp” mode. 1. Check the engine-oil level. If the level is above the “add” line, contact an Authorized Toro Service Dealer. The oil-pressure light is on and the engine rpm is low. 1. The engine-control unit has limited engine rpm, known as “limp” mode. 1. Let the engine cool and check the engine-oil level.
Problem The engine does not start, starts hard, or fails to keep running. Possible Cause 1. The fuel tank is empty. 1. Fill the fuel tank. 2. The fuel-shutoff valve is closed. 3. The oil level in the crankcase is low. 4. The throttle is not in the correct position. 2. Open the fuel-shutoff valve. 3. Add oil to the crankcase. 4. Be sure that the throttle control is midway between the slow and fast positions. 5. Replace the fuel filter. 6. Contact an Authorized Service Dealer. 5.
Problem The machine vibrates abnormally. The cutting height is uneven. Possible Cause 1. The cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. The blade mounting bolt is loose. 3. The engine mounting bolts are loose. 4. The engine pulley, idler pulley, or blade pulley is loose. 5. The engine pulley is damaged. 6. The blade spindle is bent. 7. The motor mount is loose or worn. 2. Tighten the blade mounting bolt. 3. Tighten the engine mounting bolts. 4.
SP2 SP6 SP5 SP1 BLACK RED/GREEN RED RED 2 BLACK RED/GREEN 6 12 11 5 86 9 85 F01 20A 8 START RELAY K01 87 10 30 MAIN 15A 4 3 7 1 F02 ACC FUSE BLOCK P15 A B 75 GND B P19 2 P09 2 P10 2 Electrical Schematic—Kawasaki Engines (Rev.
Electrical Schematic—Kohler Engines (Rev.
